Feminine hygiene products and apparatus and methods for making disposable products

ABSTRACT

The present invention provides a method and apparatus for increasing the number of articles processed. over a distance traveled in the machine direction of an assembly line. In particular, the orientation of the long dimension of the article is provided transverse to the machine direction, thus process rug the articles side-by-side instead of end-to-end.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of and claims priority to U.S.Provisional Patent Application Ser. No. 15/331,642, filed 21 Oct. 2016,which claims priority to U.S. Provisional Patent Application Ser. No.62/245,626, filed 23 Oct. 2015, the disclosures of which areincorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates to processes and apparatus for applyingdiscreet wings to traveling webs as the absorbent articles are orientedtransverse to the machine direction.

Generally, the absorbent articles have a long dimension and a shortdimension, whereby the articles are oriented along an assembly line withthe long dimension in line with the machine direction. As the articlesare longer than they are wide, this orientation requires more assemblyline space in the machine direction per processed article. The industrycould benefit from an alternative approach that would reduce the amountof assembly line space required in the machine direction per processedarticle to increase the number of articles processed over the samedistance traveled through the assembly line, as well as speed.

In prior art sanitary napkin production, right and left wings are oftenformed of backsheet material, and the right and left wings are foldedover the topsheet material and secured to one another for folding andpackaging. One example of a prior art sanitary napkin is shown in U.S.Pat. No. 6,391,011. In that patent, a sanitary napkin is shown havingflaps placed in a folded disposition prior to use. The flaps are formedof the backsheet material, and the flaps are unitary and coextensive onthe product with the backsheet material, so that the backsheet materialis folded about side edges of the product to present the flaps for usageand application to an undergarment. A bridge tape extending between thefolded over flaps retains the flaps in their folded configuration untiluse, at which point the bridge tape is removed, exposing adhesive forreleasably affixing the sanitary napkin to the undergarment of a wearer.

In the prior art, again as demonstrated by U.S. Pat. No. 6,391,011,absorbent cores are placed on a chassis web with the longer dimension ofthe core processed and placed onto the chassis web in a machinedirection orientation (see, e.g., FIG. 6, U.S. Pat. No. 6,391,011).

SUMMARY OF THE INVENTION

Provided is a method and an apparatus for increasing the number ofarticles processed aver a distance traveled in the machine direction ofan assembly line. In particular, the orientation of the long dimensionof the core is provided transverse to the machine direction(cross-machine direction), thus processing the articles side-by-sideinstead of end-to-end. This results in efficiency of both speed andspace. Wing material is placed onto a topsheet in a machine direction,and release papers are applied to the wing material in a relationshipadvantageous for processing and use, for instance by not requiringfolding of the wings over the side edges of the product.

A method of producing a disposable product is disclosed, the methodcomprising providing a topsheet web of material in a machine direction;coupling a first and a second wing component to said topsheet web on afirst side of said topsheet web of material; coupling a first baserelease paper to said first wing component, coupling a second baserelease paper to said second wing component, coupling a secondaryrelease paper to said first base release gaper and said second wingcomponent, providing a backsheet web of material in said machinedirection, providing an absorbent core having a length dimension and awidth dimension, said length dimension greater than said widthdimension, between said topsheet and backsheet webs, said lengthdimension of said core extending in a cross-machine direction, andcoupling said topsheet and backsheet webs about said absorbent core.

Said absorbent core is positioned underlying said first and said secondwing components, and the method may further comprise severing said firstand second wing components to create a first discrete disposableproduct. Backsheet release paper is releasably to an underside of saidbacksheet web.

A method of producing disposable products, the method comprisingcoupling a plurality of wings to a top side of a topsheet web, saidtopsheet web traveling in a machine direction; releasably coupling afirst release paper to a first edge portion of each of said wings;releasably coupling a second release paper to said first release caperand to a second portion of an adjacent wing; providing a series ofspaced cores having a length dimension, and a width dimension less thansaid length dimension, said length dimension oriented transversely tosaid machine direction; sandwiching said cores between an underside ofsaid topsheet and a top side of a backsheet traveling in said machinedirection; bonding said topsheet, and said backsheet; severing saidtopsheet and said backsheet between spaced cores to produce an absorbentarticle.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of an apparatus according to the presentinvention.

FIGS. 2-1 and 2-2 are a flow diagram of a process according to thepresent invention.

FIGS. 2A-2E show a flow diagram of sub-processes of the presentinvention, FIG. 2A shows wing material being provided, FIG. 2B showsfirs wing-release paper web formation, FIG. 2C shows second wing releasepaper formation, FIG. 2D shows a backsheet web receiving adhesive andthe combination supplied with cores formed, fluffed, debulked andembossed as shown in FIG. 2E.

FIG. 3 is a top plan view of an absorbent article according to thepresent invention along the location indicated in FIG. 1 and FIGS. 2-1and 2-2.

FIG. 4 is a top plan view of the absorbent article according to thepresent invention at the location indicated in FIGS. 2-1 and 2-2.

FIG. 5 is a cross sectional view of a preferred embodiment of theabsorbent article shown in FIG. 4.

FIG. 6 is a top view of an alternate wing arrangement for use on theabsorbent article.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIG. 1, an illustration of an apparatus 10 according tothe present invention is shown. The apparatus 10 preferably includes afirst assembly line 12 comprising a wing die-cutter 14, a firstrelease-paper slip-cutter 16, a second release-paper slip-cutter 18, ananvil 20, an ultrasonic horn 22, and a plurality of adhesive applicators24, and a second assembly line 30 comprising a core forming drum 32, acore applying drum 34, and an adhesive applicator 24. Adhesives used inthe product could include garment adhesive, fugitive adhesive (ortransport adhesive), and construction adhesive (for instance for bondingthe core to the backsheet). Cores will be placed onto constructionadhesive Placed on the backsheet.

Although a first and a second release-paper slip-cutter 16, 18 are shownand discussed, it is contemplated that one release-paper slip-cuttercould be provided to perform the steps of the first and the secondrelease-paper slip-cutters 16 18.

Looking to FIGS. 1 and 2 a process of forming an absorbent article 100(FIG. 4) according to the present invention is shown. A topsheet 40 isprovided at the first assembly line 12 and travels along the firstassembly line 12 in a machine direction 90. Wing material 42 receivesadhesive 26 (which can be a temporary, or fugitive adhesive indicated as26′) from one of the adhesive applicators 24. The wing material 42 isthen processed through the wing die-cutter 14 to provide individual wingmembers 44 (as shown in FIG. 2A) having a first wing member portion 46and a second wing member portion 48, with the adhesive 26 dividing thefirst and second wing member portions 46, 48. Each wing member 44 isthen applied to the topsheet 40 as shown Preferably adhesive 26′ carriedby wing 44 is a fugitive, or temporary bond, as ultrasonic bonding isused later in the process to couple wing 44 to topsheet 40. Alsopreferably, adhesive 26′ on wing 44 is present outside of a regionintended for ultrasonic bonding to topsheet 40. Although fugitiveadhesive 26′ is preferred, it is optional, as vacuum present on theassembly line 12 can in some instances provide holding force sufficientto retain wings 44 against web 40 during processing.

As will be discussed later, in a preferred embodiment, first and secondwing member portions 46, 48 of an individual wing member 44 ultimatelyend up on adjacent absorbent articles 100; that is, in a preferredembodiment, the wing members 44 preferably end up divided into twosections 46 and 48; first wing member portion 46 on one absorbentarticle 100, and second wing member portion 48 on a different absorbentarticle 100. Stated another way, in a preferred embodiment, portions oftwo individual wing members 44 can be used to form a single absorbentarticle 100. In a preferred production technique, one wing member 44bridges two adjacent products 100 during production. A center of wingpatch 44 (in the cross direction) is region at which a future knife cutis placed when absorbent articles 100 are cut to discrete. Duringproduction, adjacent products 100 are made discrete, dividing each wingmember 44 into two sections 46 and 48, which will become left/rightwings on adjacent products 100.

Still referring to FIG. 1 and also to FIG. 2B, a first wing-releasepaper web 60 is provided and adhesive 26 is applied by an adhesiveapplicator 24 in a predetermined pattern. Release paper typically hassilicone coating so that adhesive cannot aggressively stick to it. Inpreferred embodiments, release paper as used in the present invention isused to prevent adherence of absorbent articles 100 in an unintendedfashion. In use, absorbent articles 100 are provided with release paperswhich are removed, exposing adhesive surfaces for in-use adherence ofabsorbent articles 100 in desired places. As such, release papers 62(and as later described, release papers 66) typically carry adhesive towings 44, and also serve to cover adhesive 26 until intended productuse. The first wing-release paper web 60 is then processed through thefirst release-paper slip-cutter 16 to provide individual and spacedfirst wing-release paper members 62. Preferably, each first wing-releasepaper member 62 is adhered to a respective wing member 44 on the firstwing member portion 46 (FIG. 3), at or near a trailing edge of wingmember 44 when considered in the machine direction 90. It should benoted that although reference is made to a trailing edge in the process,the process could easily be used to apply the release paper 62 to aleading edge of wing member 44 (to in effect, create right handed orleft handed opening products in use). Also preferably, release paper 62carries a single strip of adhesive 26 either from edge to edge orclose-to-edge to close-to-edge of release paper 62 in the cross-machinedirection. In use, release paper 62 can carry away adhesive 26 whenremoved from the article 100.

Still referring to FIG. 1, and also now to FIG. 2C, a secondwing-release paper web 64 is provided and adhesive 26 is applied by anadhesive applicator 24 in a predetermined pattern. The secondwing-release paper web 64 is then processed through the secondrelease-paper slip-cutter 18 to provide individual and spaced secondwing-release paper members 66. Preferably, each second wing-releasepaper member 66 is adhered to a respective wing member 44 onto the firstwing-release paper member 62 (itself carried by first wing memberportion 46 (FIG. 3), at or near a trailing edge of wing member 44), andthen second wing-release paper member 66 overlaps adjacent wing members44, and is carried by a leading edge of a trailing wing member 44 in theprocess, as can be seen in FIGS. 3-5. In such a configuration, secondwing-release paper members 66 preferably carry adhesive 26 in two placesof advancement in the machine direction, as see in cross-section in FIG.5. In a preferred embodiment, adhesive 26 is carried by secondwing-release paper member 66 toward a leading edge of secondwing-release paper member 66 to facilitate coupling with firstwing-release paper member 62 and toward a trailing edge to facilitatecoupling with wing member 44 (see FIG. 5). Again, also preferably,release paper 66 carries these strips of adhesive 26 either from edge toedge or close-to-edge to close-to-edge of release paper 66 in thecross-machine direction.

The combination of topsheet 40, wing members 44, first wing-releasepaper members 62, and second wing-release paper members 66 continue downthe first assembly line 12. The anvil 20 and ultrasonic horn 22 thencombine to form an ultrasonic bond 28 of the wing members 44 and thetopsheet 40 preferably at a location bisecting first and second wingmember portions 46, 48 (see, e.g., FIG. 4). Additionally oralternatively, other forms of bonding now known or later developed mayperform the step of bonding the wing members 44 to the topsheet 40 andstill be within the purview of the present invention.

Concurrently with the process occurring along the first assembly line12, a pulp core 70 is being formed and a backsheet 74 is provided alongthe second assembly line 30. The core forming drum 32 receives pulp (notshown) and/or superabsorbent polymer, and in many instances acombination of both, and forms individual cores 70 each having a corelongitudinal center line 72 (see FIG. 3). Cores are produced as shown inFIG. 2E, preferably first fluffed, second debulked, and third embossed.The cores 70 are spaced apart a predetermined distance. The absorbentarticles 100 are oriented with the core center line 72 transverse, orperpendicular, to the machine direction 90. This orientation increasesthe number of articles 100 processed over a distance traveled in themachine direction of an assembly line. It also increases the number ofarticles 100 produced over a given period of time at a given machinespeed.

Typically, absorbent cores have an oblong shape designed to fitunderneath a crotch section of a wearer, generally extending from thefront of a body, under the body and to the rear of the body. Because ofthis configuration around the body of a wearer, rectangular, oblong,T-shaped or hourglass cores are commonly formed to be form fitting andcomfortable. With respect to feminine hygiene products, cores are oftenhourglass shaped or elongated oval in shape. With regard to the presentinvention, a preferred core 70 is longer than it is wide, as depictedfor example in FIGS. 3 and 4.

Additionally or alternatively, the cores 70 may be formed in any othermanner now known or later developed, including for example, through adie-cutting process (not shown).

Still referring to FIG. 1, backsheet release paper web 92 is drawn pastadhesive applicator 24 receiving adhesive 26, severed into individualbacksheet release papers 94, and coupled to an underside of backsheetweb 74. This process is also shown in FIG. 2D.

As shown in FIG. 1 the pulp cores 70 are adhered to the backsheet 74with adhesive 26 from an adhesive applicator 24 prior to being combinedwith the topsheet 40. In a preferred embodiment, construction adhesivecan be applied in full coverage by adhesive spray means to hold core 70to backsheet 74. Additionally (and optionally and alternatively), asshown in FIG. 2-1, the pulp cores 70 may be adhered by adhesive, orother types of bonding to the topsheet 40 prior to combining thetopsheet 40 and the backsheet 74. In any event, each core center line 72is preferably aligned with a corresponding border line 50 separatingneighboring wing members 44 as shown in FIG. 3.

Referring now to FIG. 2-1, an additional plan process view of theprocess shown in FIG. 1, and processes occurring after those shown inFIG. 1, is shown. Continuing from FIG. 1, the combination of topsheet 40and backsheet 74, wings 44, first release papers 62, second releasepapers 66, backsheet release paper 94 and accompanying adhesivescontinue onward together as shown in FIG. 2-1.

Referring now to FIG. 2-2, after the topsheet 40 (carrying itsassociated product components) and backsheet 74 (carrying its associatedproduct components) are introduced to one another, preferably followingthe step of bonding the wings 44 to the topsheet 40 as shown in FIG. 1,a perimeter seal 80 is formed, preferably by at least one of a heatbond, a pressure bond and an ultrasonic bond, indicated at bond 80.Referring now to FIG. 4, perimeter seal 80 forms a boundary about cores70.

Still referring to FIG. 2-2, a final die-cut is provided to form aplurality of absorbent articles 100 according to the present inventionas shown in FIG. 4. The absorbent articles 100 are then spaced apart,after which they preferably receive a web of pouch material forindividual packaging. Individual products 100, now carried by a pouchweb, are then folded along with the pouch web, and the pouch web iscrimped about the products 100. The pouch web is then itself cut tocarry an individually packaged article 100, and the individuallypackaged articles (now carried in a pouch) can be stacked packaged asdesired.

Referring now to FIG. 5, a cross-sectional view of a preferredembodiment of the absorbent article shown in FIG. 4 is shown. Verticaldashed lines represent areas in which the final die cut of FIG. 2-2 canbe employed to sever wings 44 (into their left portion 48 and rightportion 46, see FIG. 4), topsheet 40, and backsheet 70, resulting inindividual and now distinct products 100.

Referring now to FIG. 6, a top view of an alternate wing 44 arrangementfor use on the absorbent article 100 is shown. As can be seen, wings 44are not necessarily rectangular (as shown for instance with reference toFIGS. 2-4) but can be contoured, shaped or formed by die cutting orotherwise as desired.

The foregoing is considered as illustrative only of the principles ofthe invention. Furthermore, since numerous modifications and changeswill readily occur to those skilled in the art, it is not desired tolimit the invention to the exact construction and operation shown anddescribed. While the preferred embodiment has been described, thedetails may be changed without departing from the invention, which isdefined by the claims.

1. A method of producing a disposable product, the method comprising:coupling a first wing component to a first side of a topsheet web ofmaterial traveling in a machine direction; coupling a second wingcomponent to the first side of the topsheet web of material adjacentlyto the first wing component in the machine direction; coupling a firstbase release paper to the first wing component; and coupling a secondbase release paper to the second wing component and to the first baserelease paper.
 2. The method of claim 1 further comprising: coupling anabsorbent core to a backsheet web of material traveling in the machinedirection; and coupling the topsheet web of material to the backsheetweb of material, wherein the absorbent core is positioned between thetopsheet and the backsheet.
 3. The method of claim 2 further comprisingsevering the topsheet web of material to create a discrete disposableproduct comprising the first and second wing components overlying theabsorbent core.
 4. The method of claim of claim 2, wherein the absorbentcore has a length dimension and a width dimension less than said lengthdimension, wherein the length dimension is oriented transversely to themachine direction.
 5. The method of claim 1 further comprisingreleasably coupling a backsheet release paper to an underside of thebacksheet web.
 6. A method of making a disposable product, the methodcomprising: coupling a plurality of wings to a top side of a topsheetweb traveling in a machine direction; releasably coupling a firstrelease paper to a first edge portion of a first wing of the pluralityof wings; and releasably coupling a second release paper to the firstrelease paper and to a first edge portion of a second wing of theplurality of wings adjacent to the first wing.
 7. The method of claim 6further comprising: coupling a backsheet web traveling in the machinedirection to the topsheet web; cutting the topsheet web and thebacksheet web to create a discrete disposable product, wherein cuttingthe topsheet web and the backsheet web comprises: cutting through thetopsheet web, the backsheet web, and the first wing at a first cuttinglocation positioned between the first edge portion of the first wing anda second edge portion of the first wing opposite the first edge portionof the first wing; and cutting through the topsheet web, the backsheetweb, and the second wing at a second cutting location positioned betweenthe first edge portion of the second wing and a second edge portion ofthe second wing opposite the first edge portion of the second wing. 8.The method of claim 6 further comprising: positioning a core and abacksheet adjacently to the topsheet, the core having a length dimensionand a width dimension less than said length dimension, wherein thelength dimension is oriented transversely to the machine direction;coupling the topsheet to the backsheet, wherein the core is positionedbetween the topsheet and the backsheet; and severing said topsheet andsaid backsheet to create an absorbent article comprising the core andthe first and second wings.
 9. The method of claim 8 further comprisingbonding the core to one of the topsheet and the backsheet.
 10. Themethod of claim 8, wherein the first wing comprises a second edgeportion opposite the first edge portion of the first wing; wherein thesecond wing comprises a second edge portion opposite the first edgeportion of the second wing; and wherein the method further comprisessevering the topsheet and the backsheet at a first position between thefirst and second edges of the first wing and at a second positionbetween the first and second edges of the second wing to produce anabsorbent article.
 11. A method of manufacturing comprising: coupling aplurality of wing members to a top side of a topsheet web traveling in amachine direction, wherein each wing member of the plurality of wingmembers comprises a first portion and a second portion, and wherein thefirst portion of each wing member coupled to the top side of thetopsheet web is positioned adjacently to the second portion of anadjacent wing member coupled to the top side of the topsheet web;coupling a backsheet web traveling in the machine direction to thetopsheet web; cutting the topsheet web and the backsheet web to create afirst discrete disposable product, wherein cutting the topsheet web andthe backsheet web comprises: cutting through the topsheet web, thebacksheet web, and a first wing member of the plurality of wing membersat a first cutting location positioned between the first portion of thefirst wing member and the second portion of the first wing member; andcutting through the topsheet web, the backsheet web, and a second wingmember of the plurality of wing members at a second cutting locationpositioned between the first portion of the second wing member and thesecond portion of the second wing member.
 12. The method of claim 11further comprising coupling a first base release paper to the firstportion of the first wing component; and coupling a second base releasepaper to the second portion of the second wing component and to thefirst base release paper.
 13. The method of claim 12 further comprising:cutting the first base release paper from a first wing-release paperweb; and cutting the second base release paper from a secondwing-release paper web.
 14. The method of claim 11, wherein the secondwing member is adjacent to the first wing member in the machinedirection.
 15. The method of claim 11 further comprising positioning anabsorbent core between the topsheet web and the backsheet web.
 16. Themethod of claim 15 wherein the absorbent core has a length dimension anda width dimension less than said length dimension, wherein the lengthdimension is oriented transversely to the machine direction.
 17. Themethod of claim 15 further comprising forming a perimeter seal about theabsorbent core through at least the topsheet web, the backsheet web, andthe first and second wing members.
 18. The method of claim 17, whereinforming the perimeter seal comprises forming the perimeter seal via oneof a heat bond, a pressure bond, and an ultrasonic bond.
 19. The methodof claim 11 further comprising cutting the plurality of wing membersfrom a wing material.
 20. The method of claim 11 further comprisingcutting the topsheet web and the backsheet web to create a seconddiscrete disposable product, wherein cutting the topsheet web and thebacksheet web to create the second discrete disposable productcomprises: cutting through the topsheet web, the backsheet web, and athird wing member of the plurality of wing members at a third cuttinglocation positioned between the first portion of the third wing memberand the second portion of the third wing member; and wherein the seconddiscrete disposable product comprises the second portion of the secondwing member cut during creation of the first discrete disposableproduct.